JP5823216B2 - Cylindrical laminate manufacturing method and cylindrical laminate manufacturing apparatus - Google Patents

Description

  The present invention relates to a cylindrical laminate manufacturing method for manufacturing a cylindrical laminate in which a heat-fusible sheet containing a heat-fusible component is laminated in the radial direction, and a cylindrical laminate manufacturing apparatus.

  Conventionally, as a manufacturing method of a cylindrical laminated body and a manufacturing apparatus of a cylindrical laminated body, a method and an apparatus for winding a fiber sheet around a core while heat-sealing are known (see Patent Documents 1 and 2). .

JP 61-102470 A JP 55-24575 A

  When manufacturing a cylindrical laminate by pressurizing a heat-fusible sheet using a winding core and a driving roller, the length of the heat-fusible sheet supplied to the winding core is specified to achieve heat-fusibility. The supply amount of the sheet is determined, and a cylindrical laminate having a predetermined outer diameter can be obtained. However, the heat-fusible sheet has a variation in bulk density, for example, for each lot or in the length direction of the same lot. Therefore, when using a heat-sealable sheet of a different lot or partially using a heat-sealable sheet of the same lot, depending on the bulk density of the heat-sealable sheet, the outer diameter of the cylindrical laminate And variation in weight tends to occur.

  The objective of this invention is providing the manufacturing method of the cylindrical laminated body which can reduce the dispersion | variation in the outer diameter and weight of a cylindrical laminated body, and the manufacturing apparatus of a cylindrical laminated body easily.

In order to achieve the above object, the invention described in claim 1 includes a winding step of winding a heat-fusible sheet having a layer made of a fiber assembly containing a heat- fusible component onto a core while heating. A method for producing a cylindrical laminated body in which the heat-fusible sheet is laminated in the radial direction, wherein the winding step is performed on the core and the axis of the core. While pressurizing the heat-fusible sheet with a driving roller that is driven to rotate about a parallel axis, the heat-fusible sheet is continuously passed between the winding core and the driving roller, and It is a step of obtaining a semi-finished product by heating the heat-fusible sheet with the driving roller and winding it around the core until the diameter is larger than the outer diameter of the cylindrical laminate, and obtained in the winding step. The semi-finished product, together with the core, to the drive roller A diameter reduction step that adjusts to the outer diameter of the cylindrical laminate by heating and pressurizing while rotating and reducing the diameter, and the pressurization in the winding step and the diameter reduction step includes the winding core or the The gist is implemented by applying a load to the driving roller, and the diameter reduction step is a step of increasing the load more than the load in the winding step.

  According to this manufacturing method, in the winding step, the heat-fusible sheet is wound around the core while being pressed. For example, when a heat-fusible sheet having a bulk density lower than a predetermined bulk density is used, It becomes easier to compress in the thickness direction than a heat-fusible sheet having a bulk density of. Further, for example, when a heat-fusible sheet having a bulk density higher than a predetermined bulk density is used, it is less likely to be compressed in the thickness direction than a heat-fusible sheet having a predetermined bulk density. Thus, since the bulk density of the heat-fusible sheet laminated on the outer periphery of the core is adjusted by the winding process, when the outer diameter of the obtained cylindrical laminate is adjusted to a predetermined outer diameter, the cylindrical shape Variation in the weight of the laminate is suppressed. Furthermore, in the diameter reducing process, the outer diameter of the semi-finished product is adjusted to the predetermined outer diameter of the cylindrical laminate in order to reduce the diameter of the semi-finished product with a load increased from the load applied to the core in the winding process. Becomes easy.

  Invention of Claim 2 is the manufacturing method of the cylindrical laminated body of Claim 1, In the said winding process, based on the lamination | stacking thickness of the heat-fusible sheet | seat laminated | stacked on the outer periphery of the said core. The gist is that the amount of the heat-fusible sheet supplied to the winding process is determined by cutting the heat-fusible sheet.

  As the heat-fusible sheet is wound around the core, the heat-fusibility provided for the winding process is based on the thickness of the heat-fusible sheet laminated on the outer periphery of the core. Since the supply amount of the sheet is determined, it becomes easy to increase the accuracy of the weight of the cylindrical laminate.

  Invention of Claim 3 is a manufacturing method of the cylindrical laminated body of Claim 1 or Claim 2, In the said winding-up process, the pressure between the said core and the said drive roller is measured, The gist is that the diameter reduction step is started by increasing the load based on the decrease in the pressure.

  Here, in the winding process, the heat-fusible sheet is pressed at a constant pressure by applying a load to the core. In this winding process, since the heat-fusible sheet is always supplied between the winding core and the driving roller, the pressure between the winding core and the driving roller is higher than the load applied to the winding core. Become. When the supply of the heat-fusible sheet between the winding core and the driving roller is completed, the pressure between the winding core and the driving roller is reduced. In the said manufacturing method, the pressure reduction process is started by measuring the pressure between a core and a drive roller, and increasing the said load based on the fall of a pressure. Thereby, it becomes easy to start the diameter reduction process smoothly after the end of the winding process.

  Invention of Claim 4 is a manufacturing method of the cylindrical laminated body of Claim 2, Time elapsed from the cutting | disconnection of the said heat-fusible sheet | seat is time-measured with the timer, Based on the time-measurement result, the said diameter reduction The gist is to start the process.

  According to this method, the diameter reduction process can be automatically started according to the elapsed time from the cutting of the heat-fusible sheet. Thereby, it becomes easy to start a diameter reduction process smoothly.

  The manufacturing apparatus of the cylindrical laminated body of invention of Claim 5 is used for the manufacturing method of the cylindrical laminated body as described in any one of Claims 1-4, The said driving roller and the said winding An apparatus for manufacturing a cylindrical laminate comprising a pressurizing device for applying a load to a core, comprising: a detecting means for detecting a lamination thickness of a heat-fusible sheet laminated on an outer periphery of the winding core. And

  According to this configuration, based on the result of detecting the lamination thickness of the heat-fusible sheet laminated on the outer periphery of the winding core, it is matched with the predetermined outer diameter of the cylindrical laminate, that is, the diameter reduction process is terminated. It becomes easy.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a cylindrical laminated body which can reduce the dispersion | variation in the outer diameter and weight of a cylindrical laminated body is provided easily.

(A) is a perspective view which shows the cylindrical laminated body of embodiment, (b) is schematic which shows a manufacturing apparatus. (A) is a top view which shows the outline of a manufacturing apparatus, (b) And (c) is a side view which shows the outline of a pressurization part. The flowchart which shows manufacture of a cylindrical laminated body. (A)-(d) is explanatory drawing explaining the load in a manufacturing process. The time chart which shows transition about load setting, a pressure, and the displacement of a core in manufacture of a cylindrical laminated body. Schematic which shows the example of a change of a manufacturing apparatus.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.
As shown in FIG. 1A, the cylindrical laminate 11 has a columnar hollow portion and is formed by laminating a heat-fusible sheet in the radial direction. The shape of the cylindrical laminate 11 is held by heat-sealing a heat-fusible sheet that is in contact in the radial direction. The cylindrical laminate 11 of the present embodiment has an inner diameter of 40 mm or less and a thickness of 0.5 to 9.5 mm, and is used as a small filter.

<Heat-fusion sheet>
First, the heat-fusible sheet | seat used for manufacture of the cylindrical laminated body 11 is demonstrated. In this embodiment, the nonwoven fabric which is a fiber assembly is used as a heat-fusible sheet. The nonwoven fabric is configured to include heat-fusible fibers as a heat-fusible component. The heat-fusible fiber is not particularly limited as long as it contains a thermoplastic resin, and can be appropriately selected according to, for example, heat resistance and chemical resistance required for the filter.

  Specific examples of the thermoplastic resin include, for example, olefin resin, ester resin, amide resin, styrene resin, cellulose resin, vinyl resin, fluorine resin, polyphenylene sulfide, polyether ether ketone, polyether ketone, And thermoplastic polyimide. Specific examples of the olefin-based resin include, for example, polyethylene and polypropylene. Specific examples of the polyester-based resin include, for example, polyethylene terephthalate, polybutylene terephthalate, and aromatic polyester. Specific examples of the polyamide-based resin include, for example, polyamide 6 and polyamide 66. Specific examples of the styrenic resin include, for example, polystyrene, styrene-acrylonitrile copolymer, styrene-butadiene copolymer, and acrylonitrile-butadiene-styrene copolymer. Specific examples of the cellulosic resin include, for example, cellulose acetate, cellulose propionate, and cellulose butyrate. Specific examples of the vinyl resin include, for example, polyvinyl chloride, polyvinylidene chloride, vinyl chloride-vinyl acetate copolymer, polyvinyl acetate, polyvinyl alcohol, and ethylene-vinyl acetate copolymer. Specific examples of the fluororesin include, for example, tetrafluoroethylene perfluoroalkoxy vinyl ether copolymer (PFA) and polytetrafluoroethylene (PTFE).

  The heat-fusible fiber may be formed from a single kind of thermoplastic resin, or may be a composite of a plurality of kinds of thermoplastic resins. Examples of the heat-fusible fiber in which a plurality of types of thermoplastic resins are combined include a core-sheath type composite fiber and a side-by-side type composite fiber. When using non-woven fabrics composed of different types of heat-fusible fibers, from the viewpoint of maintaining the structure of the non-woven fabric, only the heat-fusible fibers having the lowest melting point are used for heat fusion. It is preferable to wear.

  Here, melting | fusing point is temperature which becomes an endothermic peak in the endothermic curve obtained by DSC (differential scanning calorimetry). In differential scanning calorimetry, the rate of temperature increase is 10 ° C./min, the temperature is raised to a temperature higher than the temperature at which the endothermic peak appears, and held at that temperature for 10 minutes, and then the rate of temperature decrease is 10 ° C./min. Then, the temperature of the endothermic peak is determined again at a rate of temperature increase of 10 ° C./min. When there is no clear endothermic peak, the softening point is used instead. The softening point is the inflection point in the endothermic curve similarly obtained by DSC.

  The non-woven fabric may be configured to include non-heat-sealable fibers as fibers other than heat-sealable fibers. Specific examples of the non-heat-bondable fiber include, for example, inorganic fiber, thermosetting resin fiber, natural fiber, and high-strength fiber. Specific examples of the inorganic fiber include, for example, glass fiber, carbon fiber, ceramic fiber, and metal fiber. Specific examples of thermosetting resin fibers include, for example, epoxy resin fibers, phenol resin fibers, unsaturated polyester fibers, polyimide fibers, and polyurethane fibers. Specific examples of natural fibers include, for example, cellulose fibers and silk fibers. Specific examples of the high-strength fibers include, for example, aramid fibers, polyarylate fibers, and polyparaphenylene benzoxazole fibers.

The non-woven fabric may contain a single kind of non-heat-fusible fiber, or may contain multiple kinds of non-heat-fusible fibers.
For the fibers constituting the nonwoven fabric, if necessary, for example, an antioxidant, an ultraviolet absorber, a light stabilizer, an antistatic agent, an anti-slip agent, an anti-blocking agent, a lubricant, a colorant, a flame retardant, a plasticizer, And a filler can also be contained.

  As a kind of nonwoven fabric, a thermal bond nonwoven fabric, a needle punch nonwoven fabric, a water punch nonwoven fabric, a melt blown nonwoven fabric etc. are mentioned, for example. The nonwoven fabric may be a wet nonwoven fabric or a dry nonwoven fabric. The nonwoven fabric may be a short fiber nonwoven fabric or a long fiber nonwoven fabric.

The basis weight of the nonwoven fabric is, for example, in the range of 10 to 100 g / m ² .
<Manufacturing equipment>
The cylindrical laminate 11 is manufactured through a winding process in which the nonwoven fabric 12 is heated and wound around the core 21. For the manufacture of the cylindrical laminate 11, a manufacturing apparatus shown in FIGS. 1B and 2A is used. The manufacturing apparatus includes a driving roller 22 that is driven to rotate about an axis parallel to the axis of the core 21.

  The core 21 is made of metal and has a diameter that matches the inner diameter of the cylindrical laminate 11 to be manufactured. In this embodiment, the diameter (outer diameter) of the winding core 21 is set to 40 mm or less in order to use the cylindrical laminate 11 as a small filter having an inner diameter of 40 mm or less. The lower limit of the diameter of the core 21 is, for example, 5 mm or more.

  The length (full length) of the winding core 21 is, for example, 300 mm to 2000 mm. When the length of the core 21 is 300 mm or more, manufacturing efficiency can be improved. On the other hand, when the length of the winding core 21 exceeds 2000 mm, the winding core 21 is likely to be bent, which may make it difficult to wind the nonwoven fabric around the winding core 21.

  The ratio (L / D) of the length (L) of the core 21 to the diameter (D) of the core 21 is preferably 20 or more, more preferably 40 or more, and further preferably 50 or more. When this ratio (L / D) is 20 or more, it becomes easy to ensure manufacturing efficiency. In addition, it is preferable that the upper limit of this ratio (L / D) is 250 or less from a viewpoint of ensuring the rigidity of the core 21.

  The drive roller 22 includes a first drive roller 22a and a second drive roller 22b located on the downstream side (downstream side in the transport direction of the nonwoven fabric 12). The first drive roller 22a and the second drive roller 22b are formed to have the same diameter, and are installed so that the axes of the drive rollers 22a and 22b are horizontal and parallel. The interval between the first driving roller 22a and the second driving roller 22b is shorter than the diameter of the winding core 21, and the winding core 21 is supported on the upper side of each driving roller 22a, 22b. Each drive roller 22a, 22b is connected to a rotation drive device (not shown), and is driven to rotate independently.

  Each drive roller 22a, 22b is independently controlled so that the surface temperature thereof becomes a predetermined temperature. As the heating means of each drive roller 22a, 22b, a well-known means using an electric heater or a heat medium can be employed. By providing a coating layer made of a plating material or a polymer material on the outer peripheral surfaces of the drive rollers 22a and 22b, durability can be increased and the frictional force of the outer peripheral surfaces can be adjusted.

  The diameter (outer diameter) of each drive roller 22a, 22b is preferably larger than the diameter of the core 21 from the viewpoint of obtaining sufficient heating efficiency and rigidity, and is twice to 40 times the diameter of the core 21. More preferably, the size is about the same.

  A pressure device 23 that pressurizes downward (each drive roller 22a, 22b) is attached to the core 21 supported by each drive roller 22a, 22b. The pressurizing device 23 includes a fluid pressure cylinder (not shown), and a predetermined load is applied to the core 21 by the operation of the fluid pressure cylinder.

  Specifically, as shown in FIG. 2A, the pressurizing device 23 includes pressurizing portions 23a and 23b disposed at both ends of the core 21, and a connecting portion 24 for connecting the pressurizing portions 23a and 23b. And. As shown in FIG. 2B, the pressurizing unit 23 a includes a pair of rotating bodies 25 that are in contact with the core 21, and pressurizes the core 21 with the rotating bodies 25. The rotating body 25 of this embodiment has a cylindrical shape, and the rotation axis thereof is positioned so as to be parallel to the core 21. The rotating body 25 transmits the pressure in the direction indicated by the arrow in FIG. The pressurizing unit 23b has the same configuration as that of the pressurizing unit 23a, and a description thereof is omitted. With such a configuration, the fluid pressure cylinder applies a load to both ends of the core 21 via the connecting portion 24 and the pressurizing portions 23a and 23b.

  As shown in FIG. 1 (b), the manufacturing apparatus is equipped with a position sensor 51 that detects the position of the core 21. The position sensor 51 measures the upward displacement of the core 21. As the position sensor 51, for example, an optical sensor, a proximity sensor, an ultrasonic sensor, or the like is used. The manufacturing apparatus is equipped with a pressure sensor 52 that measures the pressure between the winding core 21 and the drive roller 22. As the pressure sensor 52, for example, a load cell, a compression element, or the like is used.

  As shown in FIGS. 1B and 2A, a guide roller 26 that follows the first drive roller 22a is mounted above the first drive roller 22a. The guide roller 26 follows the rotational drive of the first drive roller 22a in a state where the nonwoven fabric 12 upstream of the core 21 is sandwiched between the first drive roller 22a. Thereby, the nonwoven fabric 12 is conveyed while being supplied at the peripheral speed of the first drive roller 22a.

  A cutting device 27 for cutting the nonwoven fabric 12 is provided on the upstream side of the first drive roller 22a (upstream side of the guide roller 26). As the cutting device 27, a known device including a cutting blade and a press machine can be used.

  The pressure device 23, the cutting device 27, the position sensor 51, and the pressure sensor 52 are connected to a control device. The control device is equipped with a storage unit for storing data, programs, etc. required in the manufacturing process, a calculation unit for performing various calculations, a timer for determining the amount of change per hour from the detection results of various sensors, etc. Yes.

<Production conditions>
Next, the detail of the manufacturing conditions of the cylindrical laminated body 11 is demonstrated.
(Preheating of the core 21)
It is preferable that the core 21 is preheated until it reaches a temperature higher than the melting point of the heat-fusible component contained in the nonwoven fabric 12 and higher than the temperature of the second drive roller 22b. The preheating of the core 21 is preferably performed in the range of the melting point T + 5 (° C.) to the melting point T + 45 (° C.). When the preheating of the core 21 is equal to or higher than the melting point T + 5 (° C.) of the heat-fusible component, the non-woven fabric 12 can be smoothly adhered to the core 21 by sufficiently heating the heat-fusible component. . On the other hand, when the preheating of the core 21 exceeds the melting point T + 45 (° C.) of the heat-fusible component, the heat-fusible component is excessively heated, which may increase the influence on the structure of the nonwoven fabric 12. is there. Specifically, the phenomenon that the pores of the nonwoven fabric 12 in contact with the core 21 are crushed, that is, the formation of a film, may affect the function as a filter.

  As a heating method of the winding core 21, a method of heating the winding core 21 accommodated in the container so as to reach a predetermined temperature with a heat medium such as warm air or an electric heater is suitable. Note that a rubber heater can be wound around the core 21 and heated to a predetermined temperature.

(The peripheral speed of each drive roller 22a, 22b)
The peripheral speed of the second drive roller 22b is preferably set to be faster than the peripheral speed of the first drive roller 22a. The speed difference between the peripheral speed (R2) of the second drive roller 22b and the peripheral speed (R1) of the first drive roller 22a (speed difference of each drive roller 22a, 22b = R2-R1) is 0.5 m / min or more. It is preferable that it is 1 m / min or more. When the speed difference between the drive rollers 22a and 22b is 0.5 m / min or more, the effect of increasing the compressive strength of the cylindrical laminate 11 can be easily obtained. Note that the speed difference between the drive rollers 22a and 22b is preferably 15 m / min or less, and more preferably 12 m / min or less from the viewpoint of realizing stable production.

The peripheral speed of the first drive roller 22a is preferably set in a range of 0.5 to 10 m / min from the viewpoint of ensuring manufacturing efficiency and realizing stable manufacturing.
(Temperature of each drive roller 22a, 22b)
The temperature of the first drive roller 22a is set so as to supply the nonwoven fabric 12 preheated to near the melting point of the heat-fusible component or the preliminarily heat-fused nonwoven fabric 12 to the second drive roller 22b. The temperature of the 1st drive roller 22a can be suitably adjusted so that the calorie | heat amount required for the heating of the nonwoven fabric 12 may be ensured. For example, in the case of using the high-weight nonwoven fabric 12, it is preferable to raise the temperature of the first drive roller 22a than in the case of using the low-weight nonwoven fabric 12. Moreover, the time which the 1st drive roller 22a and the nonwoven fabric 12 contact | connect changes with the conveyance speed of the nonwoven fabric 12, and the length of the nonwoven fabric 12 which has contact | connected the 1st drive roller 22a in the flow direction. In this regard, the amount of heat required for heating the nonwoven fabric 12 can be ensured by increasing the temperature of the first drive roller 22a as the time in which the first drive roller 22a and the nonwoven fabric 12 come into contact with each other is shortened.

  The temperature of the second drive roller 22b is equal to or higher than the melting point of the heat-fusible component. The temperature of the second drive roller 22b is preferably not less than the melting point T + 1 (° C.) of the heat-fusible component from the viewpoint of further strengthening the thermal fusion of the nonwoven fabric 12 and increasing the compressive strength of the cylindrical laminate 11. Yes, more preferably the melting point T + 5 (° C.) or higher of the heat-fusible component. The temperature of the second drive roller 22b is preferably in the range of the melting point T + 35 (° C.) or less of the heat-fusible component, for example, from the viewpoint of suppressing thermal denaturation of the heat-fusible component.

  The temperature of the first drive roller 22a is preferably lower than the temperature of the second drive roller 22b from the viewpoint of facilitating peeling of the nonwoven fabric 12 from the first drive roller 22a, and is less than the melting point of the heat-fusible component. It is more preferable that The temperature of the first drive roller 22a increases the peelability of the nonwoven fabric 12 from the first drive roller 22a, and promotes preheating of the nonwoven fabric 12, and the melting point T-10 (° C.) of the heat-fusible component. To the melting point T-5 (° C.).

(Relationship between preheating of core 21 and temperature of each driving roller 22a, 22b)
The temperature for preheating the core 21 is A (° C.), the temperature of the first drive roller 22a is B (° C.), the temperature of the second drive roller 22b is C (° C.), and the melting point of the heat-fusible component is T When (° C.), it is preferable to satisfy the relationship of the formula (1): A> C ≧ T> B.

(Pressure condition)
The load applied to the core 21 by the pressurizing parts 23a and 23b is 100 g / cm in terms of the linear pressure of the core 21 from the viewpoint of reducing the load on the drive rollers 22a and 22b and the core 21. Is preferably less than 50 g / cm, and more preferably less than 50 g / cm. On the other hand, the load applied to the core 21 by the pressurizing portions 23a and 23b is preferably 3 g / cm or more from the viewpoint of promoting heat fusion.

(Supply of nonwoven fabric 12)
The supply speed of the nonwoven fabric 12 is the peripheral speed of the first drive roller 22a. In the present embodiment, the nonwoven fabric 12 is sandwiched between the first drive roller 22a and the guide roller 26, thereby regulating the supply speed of the nonwoven fabric 12 and supplying and transporting the nonwoven fabric 12 at the peripheral speed of the first drive roller 22a.

<Manufacture of cylindrical laminated body 11>
Next, manufacture of the cylindrical laminated body 11 is demonstrated.
First, the roll of the nonwoven fabric 12 of the width dimension according to the length of the core 21 is prepared. By making the width dimension of the nonwoven fabric 12 into a range narrower than the interval between the pressurizing portions 23a and 23b, contact between the non-woven fabric 12 and the pressurizing portions 23a and 23b is avoided.

  Subsequently, as shown in FIG. 3, in step S <b> 101, the core load setting (load: a <b> 1) for setting the load on the core 21 by the pressurizing device 23 to a predetermined load, and the core 21 by the position sensor 51 are set. The core displacement zero setting (displacement: p0) is executed to make the detection position of zero. When the winding core load setting and the winding core displacement zero setting are completed, the winding process is started (step S102: winding start).

  In the winding process, the nonwoven fabric 12 is supplied and conveyed at the peripheral speed of the first drive roller 22a. The nonwoven fabric 12 that has passed continuously between the first drive roller 22a and the guide roller 26 is supplied between the first drive roller 22a and the core 21 while being heated by the first drive roller 22a. The nonwoven fabric 12 is heat-sealed to the preheated core 21 and is wound around the core 21. In this way, the nonwoven fabric 12 is wound around the winding core 21 once.

  The nonwoven fabric 12 that passes continuously between the core 21 and the first drive roller 22a is heated and pressurized between the core 21 and the first drive roller 22a. Thereby, the nonwoven fabric 12 preheated to near the melting point of the heat-fusible component or the nonwoven fabric 12 preliminarily heat-sealed is supplied to the second drive roller 22b.

  And the nonwoven fabric 12 which reached | attained between the core 21 and the 2nd drive roller 22b is heated and pressurized when passing between the core 21 and the 2nd drive roller 22b continuously. Thereby, the nonwoven fabric 12 is heat-sealed with the nonwoven fabric 12 already wound around the core 21.

Thus, when winding of the nonwoven fabric 12 is started in step S102, the process proceeds to step S103.
In step S103, it is determined whether or not the displacement of the core 21 has become p1. Here, as winding of the nonwoven fabric 12 around the winding core 21 proceeds, the winding core 21 and the driving roller 22 are separated from each other. That is, the displacement p1 of the winding core 21 increases in accordance with the lamination thickness of the nonwoven fabric 12 laminated on the outer periphery of the winding core 21 (the thickness of the laminated nonwoven fabric 12 as a whole).

  The displacement p1 of the winding core 21 described above is set so that the nonwoven fabric 12 is wound around the winding core 21 until the diameter of the winding core 21 is larger than the outer diameter of the cylindrical laminate 11. That is, the displacement p1 is set so as to be thicker than the thickness (wall thickness) of the cylindrical laminate 11 of the final product. The displacement p1 is preferably set in the range of 1.10 times to 1.20 times the thickness (wall thickness) of the cylindrical laminate 11 to be manufactured.

  If it is determined in step S103 that the displacement has become p1 (step S103: YES), the process proceeds to step S104. On the other hand, if it is determined in step S103 that the displacement is not p1 (step S103: NO), this step S103 is repeated.

In step S104, when the cutting of the nonwoven fabric 12 is performed by the cutting device 27, the process proceeds to step S105.
In step S105, it is determined whether or not the pressure detected by the pressure sensor 52 has become less than a threshold value. If it is determined in step S105 that the pressure is less than the threshold value (step S105: YES), the process proceeds to step S106. On the other hand, when it is determined in step S105 that the pressure is not less than the threshold value (step S105: NO), this step S105 is repeated.

Here, the threshold value in step S105 is set so as to determine whether or not the winding process has been completed. This point will be described with reference to FIG.
As shown in FIG. 4A, the pressure sensor 52 detects the pressure (referred to as pressure b1) based on the load a1 set in step S101 before the winding process. And with the start of a winding process, the core 21 is pushed up by the nonwoven fabric 12 always supplied between the core 21 and the 1st drive roller 22a. Therefore, as shown in FIG. 4B, during the winding process, the pressure sensor 52 detects a force (referred to as pressure b2) that is a combination of the load a1 and the force f that pushes up the winding core 21.

  Subsequently, when the core 21 is wound up to the end of the cut nonwoven fabric 12, as shown in FIG. 4C, the force f that pushes up the core 21 does not work. As a result, the pressure based on the load a1 (pressure) b1) is detected by the pressure sensor 52.

  When the winding process is thus completed, the pressure between the winding core 21 and the driving roller 22 decreases. For this reason, the said pressure is measured and it can be determined whether the winding process was complete | finished based on the fall of the pressure. In addition, the threshold value in step S105 is appropriately set in a range that is equal to or lower than the pressure b2 and exceeds the pressure b1.

  When the winding process is completed, a semi-finished product 11a having a larger outer diameter than that of the cylindrical laminate 11 of the final product is obtained. Subsequently, a diameter reducing step for reducing the outer diameter of the semi-finished product 11a is performed. In the diameter reduction process, the semi-finished product 11 a is heated and pressurized while being rotated by the driving roller 22 together with the core 21. As shown in FIG. 4D, the diameter reduction process is started by increasing the load a1 to the core 21 to the load a2. That is, when the load on the core 21 is changed to the load a2 in step S106, the process proceeds to step S107. The conditions of the driving roller 22 in the diameter reducing process are the same as the conditions of the driving roller 22 in the winding process.

  In the diameter reduction process, the outer diameter of the semi-finished product 11a is continued until it becomes the outer diameter of the cylindrical laminate 11 of the final product. That is, in step S107, it is determined whether or not the displacement of the winding core 21 has become a displacement p3 corresponding to the outer diameter of the cylindrical laminate 11 as the final product.

  If it is determined in step S107 that the displacement of the core 21 has become p3 (step S107: YES), the process proceeds to step S108. On the other hand, if it is determined in step S107 that the displacement of the core 21 is not p3 (step S107: NO), this step S107 is repeated.

  In step S108, the load on the winding core 21 is released and the rotation of the driving roller 22 is stopped. And the cylindrical laminated body 11 is taken out with the core 21 from a manufacturing apparatus.

  The operation in the series of manufacturing steps detailed above will be described with reference to a time chart. As shown in FIG. 5, at time t0, the pressure is b1 due to the setting of the load a1. At time t1, the pressure increases from b1 to b2 with the start of the winding process. With the start of the winding process, the core 21 is displaced, and the amount of displacement of the core 21 increases with time.

  In such a winding process, since the nonwoven fabric 12 is wound around the core 21 while being pressed, for example, when the nonwoven fabric 12 having a bulk density lower than a predetermined bulk density is used, the nonwoven fabric 12 having a predetermined bulk density is arranged in the thickness direction. It becomes easy to be compressed. For example, when the nonwoven fabric 12 having a bulk density higher than a predetermined bulk density is used, the nonwoven fabric 12 having a predetermined bulk density is less likely to be compressed in the thickness direction. Thus, the bulk density of the nonwoven fabric 12 laminated | stacked on the outer periphery of the core 21 by the winding process is adjusted.

  Subsequently, at time t2, the nonwoven fabric 12 is cut when the displacement of the core 21 reaches p1. At time t3, the pressure decreases from b2 to b1, and the winding process ends. The displacement of the core 21 at this time becomes p2 which is increased from p1 by supplying the nonwoven fabric 12 up to the site cut by the cutting device 27 and winding it.

  Thus, since the supply amount of the nonwoven fabric 12 provided for the winding process is determined based on the lamination thickness of the nonwoven fabric 12 laminated on the outer periphery of the winding core 21, the accuracy of the weight of the obtained cylindrical laminate 11 is increased. It becomes easy to raise.

  Subsequently, at time t4, the pressure is increased from b1 to b3 by being increased from the load a1 to the load a2 triggered by the pressure decrease at the time t3. Thus, the diameter reduction process is started by measuring the pressure between the winding core 21 and the driving roller 22 and increasing the load based on the decrease in pressure. For this reason, it becomes easy to start a diameter reduction process smoothly after completion | finish of a winding process.

  The diameter reduction process is continued until time t5 when the displacement of the winding core 21 reaches p3, and is terminated at this point. In this diameter reduction process, since the load applied to the core 21 is increased more than the load applied to the core 21 in the winding process, the outer diameter of the semi-finished product 11 a is matched with the predetermined outer diameter of the cylindrical laminate 11. It becomes easy.

  The cylindrical laminate 11 having the winding core 21 is taken out of the manufacturing apparatus and then subjected to a cooling process. In the cooling step, the winding core 21 around which the cylindrical laminate 11 is wound is placed in a room whose temperature is adjusted to room temperature or a predetermined temperature. By reducing the adhesion between the outer peripheral surface of the core 21 and the inner peripheral surface of the cylindrical laminate 11 by this cooling step, the core 21 can be easily extracted from the cylindrical laminate 11. .

  The cylindrical laminate 11 is cut into a predetermined length as necessary. Thereby, a plurality of filters are obtained. The obtained filter is used as an air filter for a compressed air line, for example.

According to the embodiment described in detail above, the following effects are exhibited.
(1) In the winding process, in order to wind the nonwoven fabric 12 while applying pressure, the bulk density of the nonwoven fabric 12 laminated on the outer periphery of the winding core 21 is adjusted. That is, for example, even when a non-woven fabric 12 of a different lot is used or a non-woven fabric 12 of the same lot is partially used, the variation in the bulk density of the non-woven fabric 12 is reduced by being wound around the core 21. Is done. For this reason, when the outer diameter of the obtained cylindrical laminated body 11 is matched with a predetermined outer diameter, variation in the weight of the cylindrical laminated body 11 is suppressed. Further, in the diameter reducing step, the diameter of the semi-finished product 11a is reduced by a load increased from the load applied to the core 21 in the winding step, and therefore the outer diameter of the semi-finished product 11a is set to a predetermined outside of the cylindrical laminate 11. It becomes easy to match the diameter. Therefore, it becomes easy to reduce variations in the outer diameter and weight of the cylindrical laminate 11.

  (2) Since the supply amount of the nonwoven fabric 12 provided for the winding process is determined based on the lamination thickness of the nonwoven fabric 12 laminated on the outer periphery of the winding core 21, the weight accuracy of the cylindrical laminate 11 is increased. Becomes easy.

  (3) The diameter reduction process is started by measuring the pressure between the winding core 21 and the driving roller 22 and increasing the load based on the decrease in the pressure. Thereby, it becomes easy to start the diameter reduction process smoothly after the end of the winding process.

  (4) The apparatus for manufacturing the cylindrical laminate 11 includes a position sensor 51 that detects the position of the core 21. The position sensor 51 serves as a detection unit that detects the laminated thickness of the nonwoven fabric 12 laminated on the outer periphery of the core 21. According to this structure, based on the result of detecting the laminated thickness of the nonwoven fabric 12 laminated on the outer periphery of the core 21, the predetermined outer diameter of the cylindrical laminated body 11 is matched, that is, the diameter reducing process is terminated. Becomes easy.

  (5) The cutting device 27 is preferably arranged at a position closer to the core 21, but for example, the cutting device 27 may be difficult to install, and the obtained cylindrical laminate 11 is used as the device. It may be difficult to remove from the container. Therefore, the cutting device 27 is arranged at a predetermined interval from the core 21. In this case, for example, although the time until the end of the winding process can be set to start the diameter reduction process, for example, as the peripheral speed of the driving roller 22 is changed, the diameter reduction from the cutting of the nonwoven fabric 12 is performed. Control is required to determine the time until the start of the process. In this regard, according to the method described in the above (2), since the diameter reduction process is started based on the decrease in the pressure, for example, the process management by measuring pressure is used to start the diameter reduction process. Can be controlled.

  (6) If the length of the nonwoven fabric 12 to be wound in the winding process is set according to the basis weight of the nonwoven fabric 12 to be used, the weight accuracy of the obtained cylindrical laminate 11 is increased, but the setting of the manufacturing conditions is complicated. Become. In this regard, in the manufacturing method of the present embodiment, the nonwoven fabric 12 is cut based on the displacement of the core 21. That is, by determining the supply amount of the nonwoven fabric 12 based on the displacement of the core 21, it is possible to avoid the trouble of setting the length of the nonwoven fabric 12 according to the basis weight of the nonwoven fabric 12.

(Example of change)
The embodiment may be modified as follows.
-Although the length of the nonwoven fabric 12 provided to the said winding process is determined in step S103, the fabric weight of the nonwoven fabric 12 is measured beforehand, for example, and the length of the nonwoven fabric 12 provided to a winding process according to the fabric weight is measured. You may decide.

  -The said diameter reduction process is started based on the fall of the pressure between the core 21 and the drive roller 22. FIG. For example, a sensor for detecting whether or not the nonwoven fabric 12 is supplied between the core 21 and the driving roller 22 may be provided, and the diameter reduction process may be started based on the detection result of the sensor. Further, for example, the elapsed time from the cutting of the nonwoven fabric 12 may be measured by a timer, and the diameter reduction process may be started based on the time measurement result. In this case, the diameter reduction process can be automatically started according to the elapsed time from the cutting of the nonwoven fabric 12. Thereby, it becomes easy to start a diameter reduction process smoothly. More specifically, the manufacturing apparatus is controlled so as to start the diameter reduction process when the time measurement result by the timer reaches a preset start time. The start time is calculated, for example, from the length of the nonwoven fabric 12 that has not been wound up at the time of being cut by the cutting device and the supply speed of the nonwoven fabric 12, and the time for completing the winding process is calculated. Is set to the time added.

  Note that, as in the above-described embodiment, measuring the pressure in the winding process is effective for process management, and using the measurement result of the pressure for determining the start of the diameter reduction process is a manufacturing apparatus. This is effective in that the control can be simplified.

  In the winding process, the laminated thickness of the nonwoven fabric 12 laminated on the outer periphery of the winding core 21 is detected using a position sensor 51 that detects the position of the winding core 21 as detection means. For example, the position sensor 51 that detects the position of the outermost surface of the nonwoven fabric 12 laminated on the outer periphery of the core 21 can be used as a detection unit, so that the thickness can be changed to be detected. In addition, as a detection means, the contact-type detection means which contacts the outermost surface of the core 21 or the outermost surface of the nonwoven fabric 12 laminated | stacked on the outer periphery of the core 21 may be sufficient.

  The drive roller 22 is composed of first and second drive rollers 22a and 22b. As shown in FIG. 6, the non-woven fabric 12 is heated and pressed by one drive roller 22 and the core 21. You may comprise. The drive roller 22 is a condition for the second drive roller 22b of the above embodiment.

In the manufacturing apparatus, the guide roller 26 can be omitted.
The conditions of the driving roller 22 in the diameter reducing process are the same as the conditions of the driving roller 22 in the winding process, but the condition (temperature or peripheral speed) of the driving roller 22 is changed in the diameter reducing process. May be.

  In the embodiment, the winding step is performed after the core 21 is preheated, but the preheating may be omitted. For example, the nonwoven fabric 12 may be started to be wound by temporarily fixing the nonwoven fabric 12 to the winding core 21 by applying an adhesive to at least a part of the outer peripheral surface of the winding core 21 or attaching an adhesive tape. it can.

  -Although the said pressurization part 23a, 23b is equipped with a pair of rotary body 25, as shown, for example in FIG.2 (c), the pressurization part 23a, 23b which formed the reverse V-shaped taper surface in the lower surface Can also be adopted. The outer peripheral surface of the core 21 is brought into sliding contact with the tapered surface as the core 21 rotates. The tapered surface preferably has a small resistance to rotation of the core 21 by reducing the frictional force by selecting a material and setting the surface roughness. Further, the winding core 21 may be supported by a well-known bearing structure and changed to a pressurizing unit that pressurizes through the bearing structure.

  The pressurization in the winding process and the diameter reducing process is performed by applying a load to the core 21, but a load is applied only to the driving roller 22, or both the core 21 and the driving roller 22 are applied. The pressurization can also be performed by applying a load.

  The pressurization in the winding process and the diameter reducing process is performed by applying a constant load to the core 21. For example, the winding process or the diameter reducing process may be performed by gradually increasing or decreasing the load applied to the core 21. Even in this case, the load in the diameter reduction process can be easily adjusted to the predetermined outer diameter of the cylindrical laminate 11 by increasing the load more than immediately before the completion of the winding process. It becomes. However, from the viewpoint of facilitating process management, it is preferable that the pressurization in the winding process and the diameter reducing process is performed by applying a certain load to the core 21 as in the embodiment.

  -For example, in the manufacture of a small filter having an inner diameter of 40 mm or less, since the length of the nonwoven fabric 12 used is relatively short, variations in the bulk density of the nonwoven fabric 12 tend to affect variations in the outer diameter and weight of the resulting filter. . In this respect, the manufacturing method that can easily suppress variations in outer diameter and weight is particularly effective. However, the manufacturing method may be applied to the manufacture of a cylindrical laminate having an inner diameter of more than 40 mm, and even in this case, it is effective in that variation in the outer diameter and weight of the cylindrical laminate can be reduced. is there.

  -Although the said cylindrical laminated body 11 is utilized as an air filter, it is not limited to this, You may utilize as a filter for gas other than air, or a filter for liquids. When the cylindrical laminate 11 is used as a filter, the heat-fusible sheet preferably has at least a layer made of a fiber assembly. Examples of the fiber aggregate include woven fabric and paper in addition to the nonwoven fabric 12. As the heat-fusible component, in addition to the heat-fusible fiber, for example, a fiber assembly containing an amorphous heat-fusible binder may be used. In addition, the heat-fusible sheet | seat containing the layer which consists of a fiber assembly may be the multilayered structure on which the porous film and the fiber assembly were laminated | stacked, for example.

  -The said manufacturing method can also be applied not only to manufacture of the cylindrical laminated body 11 used for a filter but to manufacture of the cylindrical laminated body used for various structural materials, for example. That is, the manufacturing method is effective as a method for manufacturing a cylindrical laminate using a heat-fusible sheet having flexibility and being able to be wound around the core 21 and having a predetermined bulk density. The thickness of the heat-fusible sheet is, for example, in the range of 0.01 to 14 mm. In this case, the heat-fusible sheet is not limited to the fiber assembly, and for example, a foam-like material, a net-like material, or the like may be used. In addition, for example, the manufacturing method is effective even when the heat-fusible sheet has a multilayer structure of a fiber assembly, a foam-like material, or a net-like material, and a resin film-like material. When the heat-fusible sheet has a multilayer structure, at least one surface of the heat-fusible sheet is composed mainly of a thermoplastic resin. When a heat-fusible sheet having only one surface has heat-fusibility is used, the surface having heat-fusibility contacts the driving roller 22 from the viewpoint of efficiently conducting heat conduction to the heat-fusible component. Thus, it is preferable to supply the winding device.

  In the manufacturing method, the winding process is performed in one stage, but the winding process can be performed in a plurality of stages. For example, after winding the first heat-fusible sheet in the first winding step, winding the second heat-fusible sheet in the second winding step, the inner peripheral side and the outer peripheral side In the above, a cylindrical laminate in which different types of heat-fusible sheets are wound can be obtained. In this case, the winding process of the manufacturing method is applied as the second winding process.

The technical idea that can be grasped from the above embodiment will be described below.
(A) Manufacture of a cylindrical laminate including a pressure sensor for measuring a pressure between the winding core and the driving roller, and starting the diameter reduction step by increasing the load based on the decrease in the pressure. apparatus.

  (B) A cutting device for cutting the heat-fusible sheet, and in the winding step, the heat to be used for the winding step by cutting the heat-fusible sheet based on the position of the core. An apparatus for manufacturing a cylindrical laminate in which the supply amount of a fusible sheet is determined.

  DESCRIPTION OF SYMBOLS 11 ... Cylindrical laminated body, 11a ... Semi-finished product, 12 ... Nonwoven fabric (heat-fusion-bonding sheet), 21 ... Core, 22 ... Drive roller, 23 ... Pressure apparatus, 51 ... Position sensor (detection means).

Claims (5)

A cylindrical shape in which a heat-fusible sheet having a layer composed of a fiber assembly containing a heat- fusible component is wound around a core while heating, and the heat- fusible sheet is laminated in the radial direction A method for producing a cylindrical laminate for producing a laminate,
The winding step
The thermal fusion sheet is pressed between the winding core and the driving roller while pressing the heat-fusible sheet by the winding core and a driving roller that is driven to rotate about an axis parallel to the axis of the winding core. A semi-finished product is obtained by continuously passing the adhesive sheet and winding the wound sheet around the core until the driving roller heats the heat-fusible sheet and expands the outer diameter of the cylindrical laminate. Is a process of obtaining
The semi-finished product obtained in the winding step includes a diameter reducing step that matches the outer diameter of the cylindrical laminate by heating and pressing while rotating with the winding core and the driving roller to reduce the diameter.
The pressurization in the winding step and the diameter reducing step is performed by applying a load to the winding core or the driving roller,
The diameter reducing step is a step of increasing the load more than the load in the winding step. In the winding process, the heat-fusible sheet used for the winding process is cut by cutting the heat-fusible sheet based on the thickness of the heat-fusible sheet laminated on the outer periphery of the core. The method for producing a cylindrical laminate according to claim 1, wherein a supply amount is determined. The said diameter reduction process is started by measuring the pressure between the said core and the said drive roller in the said winding process, and increasing the said load based on the fall of the said pressure, The said diameter reduction process is started. The manufacturing method of the cylindrical laminated body of Claim 1 or Claim 2. 3. The method for manufacturing a cylindrical laminate according to claim 2, wherein an elapsed time from the cutting of the heat-fusible sheet is measured by a timer, and the diameter reducing step is started based on the time measurement result. It is used for the manufacturing method of the cylindrical laminated body as described in any one of Claims 1-4, Comprising: The cylindrical laminated body provided with the said driving roller and the pressurization apparatus which applies a load to the said core. Manufacturing equipment,
An apparatus for producing a cylindrical laminate, comprising: a detecting means for detecting a lamination thickness of a heat-fusible sheet laminated on the outer periphery of the core.

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